Roofing



- L E RAHR ETA C' ROOFING Feb. 59

1925 Filed July le RaZ/O lill-prim 08m/Z. ZM @m I' MW'MW Patented Feb. vs, 1929.

vUNITED STATES 4iArE-trr oFFlcE.

CHESTER E. RAHR, OI!" BROOKLINE, MASSACHUSETTS, AND RALPH E. BRAKE, OF i JAMAICA, NEW YORK, ASSIGNORS, BY MESNEASSIGNMENTS, T ANACONDA SALES COMPANY, OF NEW YORK, N..Y., A CORPORATION OF DELAWARE.

Application led July 16, 1925. Serial No. 44,132.

. This invention relates toroong material of the type commonly referred to as prepared rooting, and hasto do more particularly with a novel roofing Vmaterial which affords nut5` merous advantages over the rooings heretofore made, by reasonof the presence of metal suitably applied so as to cover portions of the normally exposed area of the roofing elements. The invention also includes a process Y of making the new product. l

So-called prepared roofings, as-heretofore made and in common use, consist of a base of^a non-metallic water-resistant material, which may be made of various materials.

T6 The ordinarytype of such roofing inclu/des a base made of a sheet material of fibrous char--,

acter, such as rag felt, which is saturated and coated with a water-proofing material such as a bituminous substance, of whichasphalt is an'example. Ordinarily, a wear surface of granular material, such as crushed slate, isl

applied to the surface of theV roofing material, and partially embedded therein. The slate forms a fire and'weather-prof surface whichA protects the base and adds greatly to the life of the product. However, between the partic-les of tHe granular material, the coating substance is exposed, and occasionally, after extended periods of use, some of the granular particles may be dislodged. p

The object of this invention is to providel an improved roofing product of thetype above referred to which offers-numerous ad-v vantages over rooings as heretofore made,

stices between" the granulart particles, thusserving to bond these particles together and to the underlying coating. The metal entirely covers the interstitial coating layer, but the projecting granular particles are exposed. .The metal is preferably applied as described, by electrodeposition, 'and copper is particularly desirable, not only on account of the ease with which it may be deposited, but also because of its resistance to corrosion upon exposure to the weather, and its pleasing appearance. Bya roper selection of the gran- A color effects may be ,produced by the applio by reasjonof the use of a layer of metal which ular material to e' used, highly ornamental cation of the met-al. At the same time the cost of the new. rooiing is not materially greater than that in which no metal is used, while the durability is comparable with a metal surfaced-roofing because the only parts of the roofing. which are exposed to the weather are either the granular particles, which are not aected by exposure, or the .metal itself which has 'an indefinite life. The presence of the metal also makes the new roofing `product of increased rigidity without, however, stifening it to the point where difliculties in laying it will be encountered.

Forv a better understanding of the invention, reference will -be made to the accompanying drawings, in which,

Fig. 1 is a perspective view of a four-unit stripl shingle of common form, with metal applied throughout the surface which is eX- posed to the weather when laid in the, usual manner.

Fig. 2 is a similar view of a single shingle unit,

Fig. 3 is an enlarged Sectional vdetail on the line 3 3 of Fig. 2, with certain of the features shown diagrammatically. I l Fig. 4 is a similar sectional view of a detail showing a slightly modified construction.

With reference more particularly to Fig. 3, the base of the new roofing roduct is indicated at 1, and may consist o numerous materials. lt is here indicatedas being formed of a fibrous sheet, such as rag felt, sheeted on a paper machine and saturated with a waterproong lmaterial such asf. asphalt or otherl vbituminous products, as indicated at 2. To the surface of this base is applied a coating '3 preferably of a high 'melting point asphalt, such as blown asphalt. Over this coating is applied a layer of granular material, such as crushed slate. 5, which is partially embedded in the asphaltbyv applying the v granular material tleret'o and rollng'it into @for such parts of the coating layer as are exposed between the granular particles. The

which are effective forthe application of the isf conductingcoating on which the deposit is to be made. The most satisfactory method now known involves the application of the granular material to the base while the asphalt coating is hot, the granular material being distributed in such a way that the surface of the coating layer is not entirely covered.l Immediately after the application yof the granular material, aconductive layer of metalli-,zing powder, such, for instance, asgrap'liite, powdered metal, an-d other similar materials ordinarily employed for the purpose, is applied either by brushing the metallizing powder on the surface, so as to cover the .coating layer exposed between the granular particles, or else by dusting onthe metallizing powder. In the application of the .metallizing powder by brushing or dusting, the entire surface including the granular particles, is covered by the powder,- butthose particles of the powderl which cover the parts of the coating exppsed between the granular particles are und in place by the tacky coating surface. The surface on which the powder has been applied is nowwashe-d so that the powder which adheres to the top portions of the granular material is removed. The coated base is now placed in an electrolytic cell, and the metallizingA powder forming the conductive coating is connected in the usual way so as to form the cathode in the cell.

The deposition is carried on until a layer i of metal of thedesiredvthickness is built up,

when the element will have an appearance, as shown in Fig. 3, wherein the electro-condctive material is-shown at 4, occupying the interstices between the non-conducting granularparticles 5. The metal is deposited onlyover the conducting parts of the surface, as shown at 6, and the metal occupies the interstices between 'the granular particles and in many instances, partially overlies these particles so that the particles yare bound vfirmly together and to the base. With the rooting element so formed, it will be seen that isfactory, involves the use of the granular ysurfaced roofing of the ordinary type over` which a thin coating of asphalt emulsion is applied. Such an asphaltic emulsion is disclosed in the patent to Kirschbraun, No. 1,302,810, and vis". known in the trade as K-B, or road emulsion. Over the surface coated with this road emulsion, the metal- -lizing powder is dusted and after the stock has dried suliciently Y it is washed so as to remove the metallizing powder from the tops of the granular particles, the metallizing powder, however, still occupying the interstices between these particles. Thereafter, the deposit-ion is carried on in th-e usual manner. A slight modification of the method above described involves the brushing of the granular surfaced roofing with a fairly thick road emulsion which is allowed tol dry until .it receives its initial set, after which it is washed so that the emulsion is removed from the tops of the lgranular particles. Thereafter, the metallizing powder is brushed or dusted on and when thoroughly dry, the material is washed so that the powder is removed from the tops of the granular particles,

whereupon the stock is ready for the electrop lmetallizing powder to the stock immediately after it has been coated with the hot asphalt, and afterv a layer of metallizing powder has thus been applied, the granular material is distributed over the surface and the particles are embedded, as by rolling. After such treatment, the'base will be seen to have a layer of granular 4material and in the interstices between the granules the surface is coated Witl metallizing powder,y upon which deposition may be made in the usual way. If desired, the granular. particles and `the metallizing powder may be mixed together dry and thel resulting mixture embedded inl the surface of the asphalt coating while the latterfis still tacky. The same distribution of the conducting and non-conducting particles is thus brought` about and deposition is carried on, as before.'

Still another method involves the application of an asphalt emulsion, or some other analogous adhesive to the surface of the granular coated base. When the emulsion is dry, 'a suitable solvent is employed to clean'the tops of the granular particles and to make thea'dhesive in the interst-ices tacky, `after which the metallizing powder is dusted-or` brush-ed on. Thesurface is now washed so as to remove the powder from the 'tops of the granular particles, while leaying the conductive particles lin thel interstices. Also, the granular surface stock may be coated with graphited water, such as that known in the trade as Aquadag. The surfacev is allowed to dry,'then the 'graphite is removed from the tops of the granular particles by a brushing operation. The conductive particles', however, as before, occupy the interstices between the granular particles.

Another' method involves the production of the granular surface stock( on a roofing ma,-

chine with such a distribution of the granular substances that the asphalt coating is exposed between the granules. This product is then treated with a solvent so that the exposed portions of the asphalt layer are tacky, after which metallizing powder is applied in the usual manner.

Another method has been used involves the application of a fatty substance, as by rolling or otherwise, to the surface of a granular' coated base. The fatty substance adheres to the tops of the granules. The surface so treated is .then coated' with an asphaltemulsion which enters the interstices between the granules which have not been covered by the fatty substances. The metallizing powder is then applied by brushing or dusting and when the emulsion is dry, this conductive substance is firmly bound to the base in the interstices between the pr( jecting granules.

` The fatty substance is now washed from the tops of the granules, and the deposition is carried on in any convenient manner. Another method which is similar to one of the preceding methods in certain respects,

'involves the application of the metallizng powder to the surface of a plainstocl; which has been coated with asphalt. A thin layer of the metallizing powder is applied while the asphalt coating is still warm and tacky, and the stock is then placed in an electrolyticlcell and an extremely thin film of copper is deposited. Over the surface of the metal the granular material is now distributed,and the particles are embedded, as by rolling.. Dur: ing this operation the particles of the granular material penetrate the thin metallic film' and the edges of the metal around the-holes made by the granular material have a tendency to turn inwardly so as to bond firmly with the asphalt coating beneath the metal. rlhe metal is now exposed between the l granules, and may be ,usedas .a conducting layer on which a. further deposit of metal 'is built up by eleetrodeposition to any desired thickness. lThe second layer of metal occupies only the interstices `between the granules and acts to Wedge these granules tightly in position.

A modified-method of producing the prod-C uct involves the' use of granular material which is a mixture of conducting and nonconducting substances. T he non-conducting granular material maybe crushed slate or any of the other similar products used for the pur-f pose.4while the conducting granules may be made up of crushed petroleum coke, crushed carbon, and other`similar substances. 'The mixture includes 11M-075%' of conducting material, and the particles are suitably graded as to size. The mixtureof granular material is heated and then embedded in the surface of the stock coated with asphalt. If desired, the granular material may he applied while the 'asphalt coating is stillhot andtacky, in

which event no heating of the granular material is required. When this process is used, as illustrated in Fig. 4, the finished product includes metal l2, which is deposited only over the conductive granules l0, while the noncond'uctive granules ll are exposed through the metal layer at intervals over the surface.

By any of the methods above described, a product is produced having an exposed surface consisting either of Vmetal or else of the portions of the granular material which are exposed through the metallic layer. Neither of these substances is detrimentally affected by exposure to the weather, and the life of the new product is, therefore, much longer than that of products heretofore used, in

`which no metal is used. Also, the desired durability is secured with a minimum expense for the metal because only those portions of the exposed surface of the rooting element which might be affected by the weather, are protected by the metal.

It is preferable in carrying out any of the tlf) methods above described, for the application of the metal in the interstic'es between the granules of the granular layer, to make provision for a coating of metal over the edges of the base. This can be accomplished in several ways, as, for example, in the application of the conductive coating this coating may be extended over the edges of the base which define the area which is to be exposed to the weather. In the deposition of the metal' thereafter a layer of metal is plated over the conductive material at the edges of the base 'and is continuous with the metal coating which lies in the interstices between the granules on the face of the base. Also,

vif desired, another method for insuring that the edges are plated may be used involving the placing of the elements in stacks after the cut-outs have been formed. At this time the asphalt with which the bases are impregnated will ordinarily be sufficiently warm sol thatl the metallizing'powder when blown 0r' dusted on the edges, will be bound in position. Thereafter, when the bases are placed inthe electrolytic tank,.the metal is deposited on the edges as before.

lnthe application of the metal, the entire surface of the base may be provided with a metallic layer which occupies the interstices between the granular particles, but it 1s preferable to confine the application of the metal only to such parts of the rooting product as p will be exposed when the product is laid on the roof in the usual way. In the case of elements which are applied in overlapping courses in a manner similar to shingles but without spacing, only theforward edge of the base need be plated, as indicated by the shaded portion in Fig. 2. In the case of strip shingles inwhich cut-out indentations are formed in the forward edge, so as to dene 'a plurality of tabs, a portion of each shingle vgill be exposed through the cut-out indentations ofthe shingle in .the course next above. It is, therefore, desirable to protect this exposed portion, and this is done by eX- tending the plating rearwardly beyond the normally exposed margin of the shingle to form a plurality of tongues, as indicated in the heavy shading 'in Fig. 1: ln order to limit the metal .to the desired areas, it is only necessary to prevent its application beyond the boundaries of these areas, or this can be accomplished by restricting the electro-conductive material to the desired areas.

1We claim:

1. Sheet material comprising a b-ase having a facing of granular material, and metal lying in the interstices only of the facing.

.2. Sheet material comprising a base having a facing of granulaimaterial, and a continuous layer of metal lying only in the interstices of the facing, beyond which the particles of the granular material project.

.3. Sheet material comprising la non-metallic base having a facing of granular material and metal lying in the interstices only of said facing.

i 4. Sheet materia-l domprising a non-metall1c base having a facing of non-electro-conyductive granular material, electro-conductive material in the interstices only of said facing, and metal covering the electro-conductive material fonly. l

5. Sheet material comprising a fibrous base having a coating-of asphaltic material, a surfacing of granular `material partially embedded in this coating and metal lying in the in- (terstices only of saidsurfacing.

6.. Sheet material comprising a fibrous base having a coating of asphaltic material, asurfacing of granular material partially embedded in the coating, and electrodeposited' metal only in the interstices ofsaid surfacing.

n 7. Sheet material comprising a fibrous base having a coating of asphaltic material, a surfacing of non-electro-conductive granular material partially embedded in the coating, electro-conductive material in the interstices fof said surfacing, and electro-deposited metal on said conductive material only.

8. Sheet material comprising a fibrous hase saturated andcoated with asphaltic inaterial. a surfacing of non-electro-conductive granular material partially embedded in said coating, .electro-conductive material in the interstices of said surfacing, and electro-deposited metal on the conductive material only.

9. Roofing having a surfacing of non-me- -tallic granular material bonded by metal lying in the interstices only between the grains. 10. Sheet material surfaces with mingled electro-conductive and non-conductive materials, and' electro-deposited` metal over the conductive material only. y

11'. ln combination, a base material, non- 'comprises aiiXing granular materialfto'- the electro-conductive granular material partially embedded in the surfacethereof,electro conductive material fixed to said base between the grains of non-conductive material, and electro-deposited metal on said conductive material only.

12. In combination, a. base having a facing of non-conductive granular material fixed thereto, and deposited metal in the ining electro-conductive material in the interv sticesyonly between the grains1 and electrodepositing metal on said conductive material only.

A15. The method of facing aI surface which comprises applying a coating of hot asphaltic material over the surface, partially embedding granular material in the coating, applying electro-conductive material to the coatingv between the. granules only, and electrodepositing metal over the conductive layer only.

16. The method-of facing a surface which comprises applying a coating of hot asphaltic material over thersurface, partially embeding granular material in the coating, applying a film of electro-conductive material,u washing the. surface to remove the electroconductive material from `the tops of the granules only, `and electro-depositing metal -over the electro-conductive material only.

17. rlhe method of facingia surface which i no said surface, applying an adhesive to the granular surface, applying a film, of glectroconductive material to the interstices 'only between the granules, and electro-depositing metal over the electro-conductive material only.

18. The method of facing a surface which comprises aftiXing granular material to thesaid surface, applying `an adhesive to the granular surface, applying a lm of electroconductive material over the adherent surface, removing the electro-conductive material from the tops of the granules only` and electro-idespositing metal over the electroconductive material only. y

19. rlhe method of facing an asphaltic surface which comprises fixing thereto electroconductive and non-conductive material,'the electro-conductive material being suficient in amount to carry current over the surface, and electro-lepositimr` metal overf the conductive material only. v

20. rlfhe method offacing a surface vwhich comprises applying a coating of hot asphaltic material over the surface, applying a film' of non-metallic electro-conductive material over metallic layer Where the latter is exposed the asphaltic material, electro-depositing a between the granules.

thin film of metal over the conducting Coat In testimony whereof We ax our signa- 10 ing, partially embedding granular material tures.

5 in the surface in such manner that the granu- I lar material penetrates the thin metallic CHESTER E. RAHR. film7 and then electrodepositing metal over the RALPH E. BRAKE. 

